U.S. patent application number 15/361681 was filed with the patent office on 2017-03-16 for component delivery system utilizing film bags.
The applicant listed for this patent is PLAS-PAK INDUSTRIES, INC.. Invention is credited to Charles M. Frey.
Application Number | 20170072426 15/361681 |
Document ID | / |
Family ID | 55301456 |
Filed Date | 2017-03-16 |
United States Patent
Application |
20170072426 |
Kind Code |
A1 |
Frey; Charles M. |
March 16, 2017 |
COMPONENT DELIVERY SYSTEM UTILIZING FILM BAGS
Abstract
A dispensing apparatus includes two cylindrical sleeves, two
flexible film pack bags disposed within the sleeves, the two film
pack bags having an integrally formed rigid face plate bonded
therewith, the face plate having a discharge nosepiece integrally
formed therewith, the discharge nosepiece having a partition
internally configured to maintain separate flow streams from the
film pack bags. Two shuttles are slidingly disposed in the sleeves.
Push rods are disposed in operable communication with the shuttles.
At least one piston is disposed in operable communication with the
push rods, the piston configured to drive the push rods. A holder
is disposed proximate a front end of the sleeves, the holder
configured to restrain the face plate during dispensing of a
flowable material. A mixer is configured to be in fluid
communication with flow streams from the film pack bags. A material
applicator is disposed in fluid communication with the mixer.
Inventors: |
Frey; Charles M.; (Groton,
CT) |
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Applicant: |
Name |
City |
State |
Country |
Type |
PLAS-PAK INDUSTRIES, INC. |
Norwich |
CT |
US |
|
|
Family ID: |
55301456 |
Appl. No.: |
15/361681 |
Filed: |
November 28, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14928042 |
Oct 30, 2015 |
9517488 |
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15361681 |
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14191612 |
Feb 27, 2014 |
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14928042 |
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12378312 |
Feb 13, 2009 |
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14191612 |
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11027552 |
Dec 30, 2004 |
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12378312 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B05C 17/00583 20130101;
B05C 17/00553 20130101; B65D 81/325 20130101; B05C 17/015 20130101;
B05C 17/00516 20130101; B05C 17/00559 20130101 |
International
Class: |
B05C 17/005 20060101
B05C017/005; B05C 17/015 20060101 B05C017/015 |
Claims
1. An apparatus for dispensing a flowable material, comprising: at
least one cylindrical sleeve having a front end and a back end; an
individual one of at least one flexible film pack bag disposed
within the at least one cylindrical sleeve, the at least one
flexible film pack bag having an integrally formed rigid face plate
that is bonded to and has material common with the at least one
flexible film pack bag, the face plate having a discharge nosepiece
integrally formed therewith; at least one shuttle slidingly
disposed internal of and proximate the back end of the at least one
cylindrical sleeve; at least one push rod disposed in operable
communication with the at least one shuttle; at least one piston
disposed in operable communication with the at least one push rod,
the at least one piston configured and adapted to drive the at
least one push rod; the front end of the at least one cylindrical
sleeve configured and adapted to receive an individual one of the
at least one flexible film pack bag; a holder disposed proximate
the front end of the at least one cylindrical sleeve, the holder
configured and adapted to restrain the face plate during dispensing
of the flowable material; a mixer configured and adapted to be in
fluid communication with and on a downstream side of the at least
one flexible film pack bag; and a material applicator disposed in
fluid communication with and on a downstream side of the mixer.
2. The apparatus of claim 1, wherein: the at least one shuttle has
a circumference and a plurality of individual flexible fingers
disposed around the circumference in sliding engagement with an
interior surface of the at least one cylindrical sleeve.
3. The apparatus of claim 1, wherein: the at least one piston
comprises a piston housing; and the at least one cylindrical sleeve
is removably disposed between the piston housing and the
holder.
4. The apparatus of claim 2, wherein: adjacent ones of the
plurality of individual flexible fingers are spaced apart from each
other with gaps therebetween to permit trapped air to escape from
inside the at least one cylindrical sleeve as the at least one
shuttle slides in the at least one cylindrical sleeve from the back
end to the front end.
5. The apparatus of claim 1, further comprising: a first flexible
tube disposed in fluid communication with and on an upstream side
of the mixer, and in fluid communication with the discharge
nosepiece.
6. The apparatus of claim 5, further comprising: a second flexible
tube disposed in fluid communication with the material applicator,
the second flexible tube configured and adapted for supplying
atomization air to the material applicator.
7. The apparatus of claim 1, wherein the at least one piston is
configured and adapted to be driven by a pressurized gas.
8. The apparatus of claim 1, wherein the at least one flexible film
pack bag is formed by a method comprising: mounting a generally
tubular flexible synthetic resin film bag on a mandrel; inserting
the mandrel and bag into a mold providing a cavity about an end of
the mandrel and bag, the cavity being configured to provide the
face plate; injecting into the cavity molten synthetic resin of
substantially the same composition as that of the bag, melting an
exposed end portion of the bag using heat of the molten synthetic
resin to cause the end portion of the bag to become molten and
intermix with the molten synthetic resin to form a face plate with
the end of the bag sealingly adhered thereto with an integrated
structure of essentially uniform composition having no distinct
layers at the interface, the face plate having a discharge opening
therein and the nosepiece about the opening aligned with the end of
the bag, the face plate being overmolded on the film bag, the film
bag being disposed inwardly of the face plate; removing the face
plate, bag and mandrel from the cavity; removing the bag and face
plate from the mandrel; and sealing the end of the bag spaced from
the face plate.
9. The apparatus of claim 8, wherein: the at least one shuttle has
a circumference and a plurality of individual flexible fingers
disposed around the circumference in sliding engagement with an
interior surface of the at least one cylindrical sleeve.
10. The apparatus of claim 8, wherein: the at least one piston
comprises a piston housing; the at least one cylindrical sleeve is
removably disposed between the piston housing and the holder.
11. The apparatus of claim 9, wherein: adjacent ones of the
plurality of individual flexible fingers are spaced apart from each
other with gaps therebetween to permit trapped air to escape from
inside the at least one cylindrical sleeve as the at least one
shuttle slides in the at least one sleeve from the back end to the
front end.
12. The apparatus of claim 8, further comprising: a first flexible
tube disposed in fluid communication with and on an upstream side
of the mixer, and in fluid communication with the discharge
nosepiece.
13. The apparatus of claim 12, further comprising: a second
flexible tube disposed in fluid communication with the material
applicator, the second flexible tube configured and adapted for
supplying atomization air to the material applicator.
14. The apparatus of claim 8, wherein the at least one piston is
configured and adapted to be driven by a pressurized gas.
15. The apparatus of claim 1, wherein: the at least one cylindrical
sleeve comprises two cylindrical sleeves; the at least one flexible
film pack bag comprises two flexible film pack bags; the at least
one shuttle comprises two shuttles; the at least one push rod
comprises two push rods; each one of the two flexible film pack
bags is disposed in a respective one of the two cylindrical
sleeves; the rigid face plate is common to the two flexible film
pack bags; the discharge nosepiece has a partition internally
disposed and configured to maintain separate flow streams from
respective ones of the two flexible film pack bags; each one of the
two shuttles is slidingly disposed internal of a respective one of
the two cylindrical sleeves; each one of the two push rods is
disposed in operable communication with a respective one of the two
shuttles; the at least one piston is disposed in operable
communication with each one of the two push rods; and the front end
of respective ones of the two cylindrical sleeves is configured and
adapted to receive individual ones of the two flexible film pack
bags.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent
application Ser. No. 14/928,042 filed Oct. 30, 2015, which is a
continuation-in-part application of U.S. patent application Ser.
No. 14/191,612 filed Feb. 27, 2014, which is a divisional
application of U.S. patent application Ser. No. 12/378,312 filed
Feb. 13, 2009, which is a continuation-in-part of U.S. patent
application Ser. No. 11/027,552 filed Dec. 30, 2004, all of which
are herein incorporated by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to component packs for the
dispensing of various components via a dispenser, particularly to
component packs employing a pair of film bags containing flowable
compositions which are to be admixed when ejected from the
dispenser, and more particularly to a component delivery system
employing the pair of film bags.
[0003] Various compositions are packaged in tubular cartridges for
use in caulking guns and other types of dispensing mechanisms. In
some instances, the dispensing mechanisms will take two or more
cartridges side-by-side so that the contents of the cartridges are
dispensed simultaneously and admixed in a mixer as they flow
towards the point of deposition. Typically, such cartridges have
employed tubes of plastic, or coated or laminated paperboard, and
the like. Moreover, the tubes generally have been filled through
one end of the tube after which a closure is placed thereover.
Using such side-by-side cartridges to dispense two components
involves a substantial amount of waste and expense.
[0004] In recent years there has been considerable activity in
cartridges comprising film bags within a cylindrical shell.
Exemplary of such cartridges are those disclosed in Keller U.S.
Pat. No. 5,647,510, and the several embodiments proposed by Konuma
et al, U.S. Pat. No. 5,593,066.
[0005] Although such cartridges have represented an improvement
from the standpoint of ease of use, generally the structures have
been relatively complicated to fabricate and relatively costly.
Obtaining good seals between the bags and the face piece of the
cartridge has been a problem. Filling of the film bags and their
handling has often presented a problem in automated equipment.
[0006] An embodiment provides a novel film pack container for
dispensing components which is relatively simple to fabricate easy
to fill and relatively trouble free during the dispensing
operation.
[0007] An embodiment provides a dispensing system which is
relatively economical to fabricate and which permits dispensing of
the contents at several different times.
[0008] An embodiment provides such a dispensing system which is
readily adapted to different ratios of the components.
[0009] An embodiment provides such a dispensing system which can be
filled after assembly of the bags and the face plate.
[0010] An embodiment provides a method and mold for securing the
face plate to the film bag.
[0011] An embodiment provides a flexible component delivery system
utilizing film bags.
SUMMARY OF THE INVENTION
[0012] It has now been found that the foregoing and related objects
may be readily attained in a film pack container including an
integrally molded synthetic resin face plate having a discharge
opening and a nosepiece on one face extending about the opening. At
least one flexible synthetic resin bag has one end sealingly
adhered to the other face of the face plate about the discharge
opening, and the other ends of the bags are sealed.
[0013] Preferably, the face plate has a flange on the other face
which extends about the opening, and one end of each of the bags is
sealingly adhered to the flange. The bags and the face plate are
preferably fabricated from substantially the same synthetic resin
to obtain a good bond.
[0014] The face plate is over molded on the film bag to produce an
integrated structure of essentially uniform composition in which
the bag is disposed inwardly of the face plate and there are no
distinct layers in the interface.
[0015] In one embodiment, a pair of film pack bags each have one
end adhered to the face plate in side-by-side registry with a
portion of the discharge opening, and the discharge opening has a
divider extending therein so that the contents of the bags remain
separated as they pass through the opening. The nosepiece has a
partition therein aligned with the divider in the opening to
maintain separation of contents passing thereinto.
[0016] In another embodiment, the opening has a generally circular
periphery and the face plate includes a generally circular divider
supported within the opening to provide a generally annular
peripheral portion of the opening and a generally circular portion
spaced centrally thereof. One of the bags is of annular
configuration and has the one end sealingly adhered to the face
plate about the peripheral portion of the discharge opening, and
the other of the bags has a circular cross section and is disposed
in the center of the annular bag and in sealing engagement with the
circular divider. The face plate has a nosepiece thereon extending
from the discharge opening and a circular partition corresponding
to the divider to maintain separation of the contents passing
thereinto.
[0017] The film pack containers are filled with flowable
compositions and will normally have a sealing cap on the end of the
nosepiece which is replaced by a static mixer when discharging the
contents.
[0018] In use, the filled film bag container is mounted in a
dispenser including a housing with a dispensing end, a tubular
sleeve, and a shuttle is movable in the sleeve towards the
dispenser end. The film pack which is disposed in the tubular
sleeve can be removed so that the sleeve can be reused.
[0019] In a method for producing dispenser packs of flowable
compositions, a generally tubular flexible synthetic resin bag is
supported on a mandrel, and the mandrel and bag are inserted into a
mold providing a cavity about the end of the mandrel and bag; the
cavity is configured to provide the face plate and nosepiece.
Molten synthetic resin of substantially the same composition as
that of the bag is injected into the cavity to form a face plate
with the end of the bag sealingly adhered to the inner face
thereof. The face plate has a discharge opening therein and a
nosepiece about the opening is aligned with the end of the bag. The
face plate, bag and mandrel are received from the cavity, the bag
and face plate are removed from the mandrel, and the end of the bag
spaced from the face plate is sealed. A flowable composition is
injected through the nosepiece and opening in the face plate and
into the bag, and a sealing cap is mounted on the nosepiece.
[0020] In one embodiment, a pair of synthetic resin bags are
mounted on a pair of mandrels which are cooperatively configured
and cooperate to define a generally circular cross section when
placed in a cylindrical sleeve. The mold cavity and mandrels are
configured to provide a partition in the opening in the face place
and a nosepiece separating the contents of the two bags as the
compositions in the bags flow therethrough. Flowable compositions
are injected into each of the bags through the nosepiece.
[0021] In another embodiment, a pair of synthetic resin bags are
mounted on a pair of mandrels, one of which is annular cross
section and the other is of circular cross section and disposed
within the annular mandrel. The mold cavity is configured to
provide a face plate with a partition in the opening and nosepiece
separating the contents of the two bags as the composition in the
bags flow therethrough.
[0022] In another embodiment, an apparatus for dispensing a
flowable material includes: at least two cylindrical sleeves each
having a front end and a back end; at least two shuttles slidingly
disposed internal of and proximate the back end of respective ones
of the at least two cylindrical sleeves; at least two push rods
disposed in operable communication with respective ones of the at
least two shuttles; and, at least one piston disposed in operable
communication with the at least two push rods, the at least one
piston configured and adapted to be driven by a pressurized gas.
The front end of respective ones of the at least two cylindrical
sleeves are configured and adapted to receive individual ones of
two flexible film pack bags having a common rigid face plate, the
face plate having a discharge nosepiece integrally formed
therewith, the discharge nosepiece having a partition internally
disposed and configured to maintain separate flow streams from
respective ones of the two flexible film pack bags. A holder is
disposed proximate the front end of respective ones of the at least
two cylindrical sleeves, the holder configured and adapted to
restrain the face plate during dispensing of the flowable material.
A mixer is configured and adapted to be in fluid communication with
the flow streams from respective ones of the two flexible film pack
bags. A material applicator is disposed in fluid communication with
and on a downstream side of the mixer. A first flexible tube is
disposed in fluid communication with and on an upstream side of the
mixer. A second flexible tube is disposed in fluid communication
with the material applicator for supplying atomization air to the
material applicator via the pressurized gas.
[0023] In another embodiment, an apparatus for dispensing a
flowable material includes: at least two cylindrical sleeves each
having a front end and a back end; two flexible film pack bags,
each film pack bag being disposed within respective ones of the at
least two cylindrical sleeves, the two flexible film pack bags
having an integrally formed common rigid face plate that is bonded
to each of the two flexible film pack bags, the face plate having a
discharge nosepiece integrally formed therewith, the discharge
nosepiece having a partition internally disposed and configured to
maintain separate flow streams from respective ones of the two
flexible film pack bags; at least two shuttles slidingly disposed
internal of and proximate the back end of respective ones of the at
least two cylindrical sleeves; at least two push rods disposed in
operable communication with respective ones of the at least two
shuttles; at least one piston disposed in operable communication
with the at least two push rods, the at least one piston configured
and adapted to drive the at least two push rods; the front end of
respective ones of the at least two cylindrical sleeves configured
and adapted to receive individual ones of the two flexible film
pack bags; a holder disposed proximate the front end of respective
ones of the at least two cylindrical sleeves, the holder configured
and adapted to restrain the face plate during dispensing of the
flowable material; a mixer configured and adapted to be in fluid
communication with the flow streams from respective ones of the two
flexible film pack bags; and a material applicator disposed in
fluid communication with and on a downstream side of the mixer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a longitudinal view in partial section of a
cartridge dispenser in which there is seated a film pack container
in accordance with an embodiment of the invention;
[0025] FIG. 2 is a sectional view the film pack container and
dispenser along the line 2-2 of FIG. 1;
[0026] FIG. 3 is a longitudinal sectional view of the film pack
container of FIG. 1;
[0027] FIG. 4 is a side elevational view of a face plate of the
film pack container;
[0028] FIG. 4a is a rear view of the face plate of the film pack
container shown in FIGS. 2 and 3;
[0029] FIG. 5 is a front view of the face plate of the film pack
shown in FIGS. 2 and 3;
[0030] FIG. 6 is a longitudinal sectional view of an alternate
embodiment of the film pack container in accordance with an
embodiment of the invention;
[0031] FIG. 7 is a front view of the face plate of FIG. 6;
[0032] FIG. 8 is a rear view of the face plate of FIG. 6;
[0033] FIG. 9 is a diagrammatic view of film bags mounted on
coaxial mandrels and disposed within a mold to form the face
plate;
[0034] FIG. 10 is a view similar to FIG. 9 for making a film pack
container with side-by-side bags;
[0035] FIG. 11 is a diagrammatic view of the film bag/face plate
assembly with a dispenser tube coupled to the face plate for
introduction of a flowable composition into one of the bags;
[0036] FIGS. 12a and 12b are respectively side and rear elevational
views of a cap for use in accordance with an embodiment of the
invention;
[0037] FIGS. 13a and 13b are respectively side and front views of a
coupler for use in accordance with an embodiment of the
invention;
[0038] FIG. 14 is a longitudinal view of a static mixer for use in
accordance with an embodiment of the invention;
[0039] FIG. 15 is a diagrammatic illustration of a mold cavity film
and overmolded face plate in accordance with an embodiment of the
invention;
[0040] FIG. 16 is a drawing of a dual film bag prior to filling and
sealing of the lower end in accordance with an embodiment of the
invention;
[0041] FIGS. 17a and 17b are drawings of a fragmentary single bag
in accordance with an embodiment of the invention;
[0042] FIG. 18 is a drawing of a single bag from what is understood
to be a licensee of Konuma and made in accordance with U.S. Pat.
No. 5,593,066;
[0043] FIG. 19 is a drawing of an enlarged fragmentary portion of
the film bag of FIG. 18 with a base closure member engaged with the
lower end of the tubular film bag;
[0044] FIG. 20 depicts a first portion of a component delivery
system utilizing film bags in accordance with an embodiment of the
invention;
[0045] FIG. 21 depicts a second portion of the component delivery
system in accordance with an embodiment of the invention;
[0046] FIG. 22 depicts a partially assembled state of the film bags
of the first portion partially installed into sleeves of the second
portion of the component delivery system in accordance with an
embodiment of the invention;
[0047] FIG. 23 depicts an enlarged view of the mixing and
dispensing section of the first portion of the component delivery
system in accordance with an embodiment of the invention;
[0048] FIG. 24 depicts an alternative arrangement of sleeves, film
bags and shuttles, in accordance with an embodiment of the
invention; and
[0049] FIG. 25 depicts the alternative sleeves of FIG. 24 being
utilized in a cartridge dispenser similar to that depicted in FIG.
1.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT
[0050] Turning first to FIG. 1, therein illustrated a conventional
caulking gun generally designated by the numeral 10 in which is
seated a filled film bag container embodying an embodiment of the
invention and generally designated by the numeral 12 (also herein
referred to as film pack container). The caulking gun 10 has an
arcuate housing 14, an end plate 16, a piston/rod 18 and an
actuator assembly 20. Disposed in the housing 14 is the film bag
container 12 which is supported in the cylindrical sleeve 22, and a
cylindrical shuttle 24 which is moved in the sleeve 22 against the
film bag container 12 by the piston/rod 18.
[0051] Turning next to FIGS. 2-5, therein illustrated is a film bag
container 12a embodying an embodiment of the invention in which
there is an outer annular bag 26, an inner cylindrical bag 28 and a
face plate generally designated by the numeral 30 to which one end
of the film bags 26, 28 are adhered. The face plate 30 has
rearwardly projecting flanges 32 which provide the surface to which
the film bags 26, 28 are adhered, and a discharge opening generally
designated by the numeral 34. Extending about the discharge opening
34 and extending forwardly is a nosepiece generally designated by
the numeral 36. The opposite ends of the film bags 26, 28 are
sealed as indicated by the cross hatching 38.
[0052] As seen in FIGS. 4 and 5, the discharge opening 34 in the
face plate 30 allows the contents of the film bag 26 to flow
through the portion 40, and the contents of the film bag 28 flow
through the portion 42.
[0053] The passage through the nosepiece 36 has a partition 48
which maintains the separation of the two streams until they enter
the static mixer generally designated by the numeral 50 and which
is secured onto the nosepiece 36.
[0054] Turning next to FIGS. 6-8, this film bag container 12b has a
pair of generally cylindrical film bags 52,54 of different cross
sectional area (about 3:1, for example but not limited to such).
One end is adhered to the flanges 56 of the face plate generally
designated by the numeral 58. As in the first embodiment, there is
a discharge opening generally designated by the numeral 60 and a
nosepiece 62 which extends thereabout. The opening 60 has a
partition 64 so that the contents of the film bag 52 flow through
the portion 66 and the contents of the film bag 54 flow through the
portion 68. The nosepiece 62 has a cooperating and aligned
partition 70, and the opposite ends of the film bags are sealed as
indicated by the numeral 72.
[0055] Turning next to FIG. 9, therein schematically illustrated is
the mold assembly for integrally molding the face plate 30 about
the ends of the coaxial film bags 26, 28 and bonding the components
in assembly. Seated in a complimentary cavity 74 in a mold 76 are
an annular mandrel 78 and a coaxial cylindrical mandrel 80 upon
which are slidably supported the annular film bag 26 and the
cylindrical film bag 28. The mandrels 78, 80 are supported on the
base 82, and a secondary core 84 extends downwardly to cooperate
with the mandrels 78, 80 to provide a cavity portion 86
corresponding to the configuration desired for the face plate
30.
[0056] Molten synthetic resin is injected into the cavity portion
86 through runners (not shown) to produce the desired face plate 30
including the flanges 32, discharge opening 34 and nosepiece 36.
The molten resin heats the exposed end portions of the film bags
26, 28 to effect a strong bond between the film bags 26, 28 and
face plate 30. After cooling, the mold 76 is opened and the mandrel
fixture is withdrawn. The film bags 26, 28 are slid off the
mandrels 78, 80 and the opposite ends of the film bags are sealed
to provide an empty film pack container.
[0057] Turning next to FIG. 10, therein illustrated is the mold
assembly for molding and bonding the film bags 52, 54 to the face
plate 58 for the embodiment of FIGS. 6-8. A large diameter mandrel
88 and a small diameter mandrel 90 are supported on the base 92 and
have the film bags 52, 54 supported thereon in the cavity 94 of the
mold 96. The secondary core 98 cooperates with the mold cavity 94
to provide a cavity portion in which the ends of the film bags 52,
54 are exposed so that resin will flow thereabout to form the face
plate 58 and bond the components. After cooling, the mandrel
assembly is withdrawn from the mold 96 and the face plate and film
bags are removed therefrom to provide the empty film pack
container.
[0058] Turning next to FIG. 11, an empty film pack container 12a is
supported on a fixture (not shown), and air is evacuated from the
film bags 52, 54. A first flowable composition is injected into the
small film bag 54 through the fill tube 100 which is seated in the
face plate 58. Generally, the flowable composition will extend into
the nosepiece 62. After the film bag 54 is filled, a similar fill
tube (not shown) is inserted into the nosepiece 62 and a flowable
composition is injected into the large film bag 52.
[0059] Turning now to FIGS. 12a and 12b, and FIGS. 13a and 13b,
after the film bags have been filled, the cap generally designated
by the numeral 102 is secured to the nosepiece 62 by the internally
threaded coupler generally designated by the numeral 104 which
bears against a flange 106 on the cap 102 and threads onto the
nosepiece 62. The cap 102 has portions 108 which extend into the
nosepiece 62.
[0060] The coupler 104 also serves to mount the static mixer
generally designated by the numeral 110 since the coupler 104 bears
against the flange 112 of the mixer 110.
[0061] FIG. 16 is a drawing of a dual film pack container sold
commercially by Applicant's assignee. The film bags are side by
side and the face plate is disposed about the end of the tubular
film bags.
[0062] FIG. 17a is a drawing of a dual film bag and face plate.
[0063] FIG. 17b is a drawing of an enlarged fragmentary portion of
FIG. 17a.
[0064] FIG. 18 is a drawing of a single film bag container made in
accordance with the Konuma et al patent.
[0065] FIG. 19 is an enlarged fragmentary view of the Konuma film
bag reinforcing member assembly. The film bag is placed about the
periphery of the reinforcing member and is adhered to the outer
surface of the reinforcing member.
[0066] By supporting the upper ends of the mandrel in a properly
configured mold cavity, the molten resin will flow about the upper
end of the film bag and cause it to become molten and intermix with
the molten resin flowing into the cavity.
[0067] As used herein, the term "discharge" opening includes single
partitioned openings and spaced, separate openings. The
configuration and size will vary with the volume to flow
therethrough and the film bag configuration.
[0068] As used herein, the term "synthetic resin" includes
homopolymers and interpolymers, and various additives including
fillers, reinforcing elements, etc. In the instance of the film
bags, it includes not only homogenous films but also laminates of
different resins with and without additives. A preferred resin is
polypropylene, but polyethylene and nylon may also be used. For
some applications, it is desirable to use a composite film with a
center layer of nylon and inner and outer layers of
polypropylene.
[0069] As used herein, the term "substantially identical"
composition refers to resins of similar chemistry which will bond
strongly. In the instance of laminates, the resin layer providing
the surface of the bag to be bonded to the face plate should be
substantially identical to that of the resin of the face plate so
that the bag will firmly bond thereto.
[0070] The film bags are generally formed from tubular film cut to
the desired length. Although blown film is preferable, flat film
may be formed into a tube with bonded overlapping edges.
[0071] Bonding of the ends of the bags remote to the face plate can
be effected by adhesives, heat, sonic welding, and other readily
available techniques.
[0072] Applicant's process of overmolding the face plate on the
exterior of the film eliminates secondary operations with premolded
members.
[0073] It can be seen that an embodiment of the present process
permits use of film bags of laminated films including one or more
resins providing desired properties such as resistance to attack by
the contents better bonding and mixing of the resins of the film
and face plates.
[0074] In contrast, microscopic analysis of the film/reinforcing
member of Konuma shows multiple defined layers, whereas the
overmolding in accordance with an embodiment of the invention
produces an integrated structure of essentially uniform composition
in which the film bag is disposed inwardly of the face plate and
there are no distinct layers at the interface.
[0075] Various flowable compositions may be used in the film packs
including sealants, adhesives, protectants, paints and other
coating materials, foams, etc. The film bag exposed thereto and the
face plate should have a composition which will not be adversely
affected thereby.
[0076] The mixed components exiting the static mixer can be applied
directly or sprayed by use of a pressurized air source and a
suitable nosepiece assembly, which is discussed further below.
[0077] The dimensioning (cross sectional area) of the bags in a
film pack will allow proportionating the two components to be
mixed. For a 1:1 ratio, the film bags have the same cross sectional
area. For a 3:1 ratio, one of the film bags will have a cross
sectional area which is three times that of the other. When the
relative viscosity of the compositions or the ratios warrants, the
discharge openings may also be customized to facilitate or retard
flow therethrough.
[0078] The discharge opening may assume several different
configurations but should provide partitioning of the flowable
compositions until after they have passed into the nosepiece.
Moreover, the configuration and dimensioning of the separate
portions may provide a restriction for one of the flowable
compositions to accommodate variation in viscosity, different
ratios, etc.
[0079] The film bags are filled by injecting the flowable
compositions through the discharge opening(s). After sealing the
opposite end of the film bags, the face plate can be mounted on a
fixture which allows the film bags to extend vertically downwardly.
A vacuum may be drawn on the film bags through the nosepiece to
facilitate the filling of the film bags without having to vent air
from the film bags as they are being filled, or a nitrogen purge
may be used. Alternatively, the film bags may have a porous vent to
permit air to pass therethrough but not the composition being
introduced into the film bag.
[0080] The dispensers conveniently use as sleeves cylindrical tubes
of synthetic resin, spiral wound paperboard, metal and laminates
which can be reused. By use of shuttles acted on by the pusher of
the piston, the shuttles are moved in the sleeve against the film
bags to compress them. When the film packs are only partially
discharged, the static mixer can be removed and discarded, and the
cap is placed on the nosepiece. If the contents are fully
discharged, the static mixer is removed and the film pack can be
removed from the sleeve; both are discarded. A new film pack can be
placed in the sleeve which is rotated end for end before placement
in the dispenser. Thus, the shuttle is at the opposite end of the
dispenser to be acted upon by the pusher of the piston when the
sleeve and film pack container are placed in the dispenser.
[0081] Thus, the discharged film pack containers and static mixers
are discarded, but the dispensers, sleeves and shuttles are all
reusable.
[0082] Thus, it can be seen from the foregoing detailed description
and attached drawings that the film bag containers according to an
embodiment of the invention are relatively simple to fabricate and
the components are bonded to provide good sealing. The film bags
can be filled easily after assembly of the components.
[0083] Turning now to FIGS. 20-25 in which alternative component
delivery systems that utilize the aforementioned film bags are
depicted.
[0084] FIG. 20 depicts a first portion 200 of a component delivery
system that utilizes two flexible film bags 202, 204 (similar to
film bags 26, 28). The two flexible film pack bags 202, 204 have a
common rigid face plate 206 (similar to face plate 30) with a
discharge nosepiece 208 (similar to nosepiece 36) integrally formed
therewith. The discharge nosepiece 208 has a partition (best seen
with reference to partition 48 in FIG. 3) internally disposed and
configured to maintain separate flow streams from respective ones
of the two flexible film pack bags 202, 204. A mixer 210 (similar
to static mixer 50) is disposed in fluid communication with the
flow streams from respective ones of the two flexible film pack
bags 202, 204 via a first flexible tube 212 disposed on an upstream
side of the mixer 210. In an embodiment, the flexible tube 212 is a
single tube that fluidly connects the mixer 210 to the nosepiece
208, and can be of any length suitable for a purpose disclosed
herein, which typically would be a length limited by the potting
time of the two components from the two film bags 202, 204 as they
travel, and partially mix while they travel, through the flexible
tube 212. In an embodiment, a material applicator 214, such as a
spray tip for example, is disposed in fluid communication with and
on a downstream side of the mixer 210. A second flexible tube 216
(depicted as a partial length in FIG. 20) is disposed in fluid
communication with the material applicator 214 for supplying
atomization air to the material applicator 214 via pressurized
gas.
[0085] FIG. 21 depicts a second portion 300 of the component
delivery system. In an embodiment, the second portion 300 includes
two side-by-side cylindrical sleeves 302 (only one visible in FIG.
21) each having a front end 304 and a back end 306, two shuttles
308 (best seen with reference to FIG. 24) (similar to shuttle 24)
are slidingly disposed internal of and proximate the back end 306
of respective ones of the two cylindrical sleeves 302. The two
cylindrical sleeves 302 are substantially rigid as compared to the
flexible film bags, 202, 204, and can be of any material suitable
for a purpose disclosed herein, such as aluminum as depicted in
FIG. 21, or plastic as depicted in FIG. 24, which is discussed
further below. Two side-by-side push rods 310 (only one visible in
FIG. 21) are disposed in operable communication with respective
ones of the two shuttles 308, and driven by a piston 312 that is
disposed in operable communication with the two push rods 310.
Pressurized gas 400 is utilized to drive the piston 312 via a
pressurized gas line 402. Flow of the pressurized gas 400 is
controlled via a trigger 322. In an embodiment, the pressurized gas
400 is provided by an air compressor for example. The piston 312
has a piston housing 316, and the two cylindrical sleeves 302 are
fixedly attached to the piston housing 316. Another end of the
second flexible tube 216 is depicted in FIG. 21 connected to the
same source of pressurized gas 400. As best seen with reference now
to FIG. 22, the front ends 304 of respective ones of the two
cylindrical sleeves 302 are configured and adapted to receive
individual ones of the two flexible film pack bags 202, 204, which
are inserted into the front end 304 of the sleeves 302. In an
embodiment, a holder 314 is disposed proximate the front end 304 of
respective ones of the two cylindrical sleeves 302 and is
configured and adapted to restrain the face plate 206 during
dispensing of the flowable material inside the two film pack bags
202, 204. The holder 314 is securable to the two cylindrical
sleeves 302 via hardware 318, and movable with respect thereto,
pivotable for example, to facilitate loading of the film bags 202,
204 into the two cylindrical sleeves 302.
[0086] Reference is now made to FIG. 23, which depicts an enlarged
view of the mixing and dispensing section of the first portion 200
of the component delivery system in accordance with an embodiment
of the invention. The flowable material from the film pack bags
202, 204 when dispensed via the second portion 300 travel through
the flexible tube 212 and through the mixer 210 to the material
applicator 214 (spray tip for example). Atomization air from the
pressurized gas 400 is provided to a trigger assembly 220 via the
flexible tube 216. Actuation of a trigger switch 222 permits the
pressurized gas to travel through the connecting tube 224 and the
coupling 226 to provide atomization air at the material applicator
214. In an embodiment where the material applicator 214 is a spray
tip, the atomization air facilitates spraying of the flowable
material, and the flexible tube 216 facilitates spraying in close
quarters, such as below ground through a manhole cover for
example.
[0087] As mentioned above, the two cylindrical sleeves 302 can be
made from any material suitable for a purpose disclosed herein. In
FIGS. 21 and 22, example cylindrical sleeves 302 were made from
aluminum. With reference now to FIG. 24, an alternative arrangement
of two cylindrical sleeves 352, film bags 202, 204, and shuttles
308 is depicted, where the two cylindrical sleeves 352 are made
from plastic. Assembly of the film bags 202, 204 into the sleeves
352 is similar to that discussed in connection with FIG. 22, where
the two shuttles 308 are inserted into the back ends 356 of the
sleeves 352, while the film bags 202, 204 are inserted into the
front ends 354 of the sleeves 352. The combination of the film bags
202, 204 in the cylindrical sleeves 352 acts like the film bag
container 12 and sleeve 22 in FIG. 1, where the sleeves 352 are
also reusable and the expended film bags 202, 204 are disposable.
When the combination is assembled into a cartridge form via the
sleeves 352, and the film bags 202, 204 are filled with flowable
material (discussed above), a sealing cap 218 is placed over the
nosepiece 208 to prevent leakage and premature curing of the
flowable material inside the film bags 202, 204.
[0088] To facilitate dispensing of the flowable material from the
film bags 202, 204 in the sleeves 352, and with reference now to
FIG. 25, a caulking gun type dispenser 380 suitable for dispensing
flowable material from a cartridge is employed (similar to the
caulking gun 10 in FIG. 1). Similar to the dispensing action
discussed above in connection with FIG. 21, the shuttles 308 inside
sleeves 352 are driven by two push rods 360, which are driven by a
piston (similar to piston 312 for example), which in turn is driven
by pressurized gas 400.
[0089] With reference now back to FIG. 24, each shuttle 308 has a
shape similar to that of a cylindrical disk with an outer
cylindrical circumference, and a plurality of individual flexible
fingers 320 disposed around the outer circumference. When the
shuttles 308 are assembled into their respective sleeves 302, 352,
the plurality of flexible fingers 320 of each shuttle 308 flex
radially inward in a non-sealing sliding engagement with an
interior cylindrical surface of each respective sleeve 302, 352.
Spacing between adjacent ones of the flexible fingers 320 permits
trapped air inside the sleeves 302, 352 (i.e., between the shuttles
308, sleeves 302, 352, and film bags 202, 204) to escape during a
dispensing operation.
[0090] While the invention has been described with reference to
example embodiments, it will be understood by those skilled in the
art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiments disclosed as the best or only mode
contemplated for carrying out this invention, but that the
invention will include all embodiments falling within the scope of
the appended claims. Also, in the drawings and the description,
there have been disclosed example embodiments of the invention and,
although specific terms may have been employed, they are unless
otherwise stated used in a generic and descriptive sense only and
not for purposes of limitation, the scope of the invention
therefore not being so limited. Moreover, the use of the terms
first, second, etc. do not denote any order or importance, but
rather the terms first, second, etc. are used to distinguish one
element from another. Furthermore, the use of the terms a, an, etc.
do not denote a limitation of quantity, but rather denote the
presence of at least one of the referenced item.
* * * * *